Alireza Bayramvand | Portfolio 2024 by Alireza Bayramvand

2016 - 2022 + 2023

PORTFOLIO Alireza Bayramvand Ann Arbor, Michigan, USA

Email Number

Alirezab@umich.edu +1 734 757 5551 1

Computational Design Method Perspolis Entrance Pavilion 2019

Jul. 2016 -Mar. 2017

Computational Designer, Geometrical Rationaliation Marvdasht, Fars, Iran

Hedracrete

Participant CAAI, Tehran, Iran

Tial Al Irfan Competition Competition The Alliance, Tehran, Iran

Jul. 2020

Planar Hexagonal Meshing

Research Development and Implementation The Alliance, Tehran, Iran

Nov. 2019

StressNav Precision

Computational Designer Taubman College, Michigan, USA

Mar. 2023

Medial Space

Workshop tutor Arj Innovation School, Tehran, Iran

Forma Participant

Contents

Denver, Colorado, USA

18 22 28

Jul. 2019

Oct. 2025

Robotic Assembly PSCo. Pavilion

Computational Designer, Toolpath Designer The Alliance, Tehran, Iran

May. 2018

Sep. 2020

TNSB Pavilion

Professional Tehran.fabtory & The Alliance Tehran, Iran

Digital Plastic Research Plastic Architecture Researcher Dart Lab, Michigan, USA

Generative Mix Researcher, Robotic 3D Printing Specialist Dart Lab, Michigan, USA

Nov. 2022

Digital Concrete Research Shell Wall Researcher, Robotic 3d Concrete Printing Specialist DART Lab, Michigan, USA

Branch Wall Researcher, Robotic 3d Concrete Printing Specialist DART Lab, Michigan, USA

Feb. 2023

Jun. 2023

Robotic Assembly Hot Blade Cutting [9 Axis] Researcher, End-effector Dsigner The Alliance, Tehran, Iran

Dec. 2019

Perspolis Entrance Pavilion Computational Designer, Geometrical Rationaliation Marvdasht, Fars, Iran 2019 Press: https://www.archdaily.com/963277/persepolis-entrance-pavilion-theallianc 4

Design Process The design goal of the project was to design and build a 200m2 space with two sub-spaces and one entrance that could serve as a multifunctional space for different activities of the Persepolis World Heritage site, such as holding exhibitions or lectures. The designed form is based on mathematical and geometrical rules of Medial Surfaces and their potential of dividing space into sub-spaces in a more dynamic way comparing to traditional approaches of space divisions. The problem with these kinds of doubly curved surfaces is the fabrication cost. So, after designing the base form a set of mathematical and geometrical rules and algorithms were applied for extracting the conjugated curve network of the surface that later could be useed as the underlying guide for converting a doule-curved surface into a system of planar quad panels. 6

My Role and Impact The primary project challenge centered around a limited budget. Conventional fabrication methods for intricate doubly curved panels (CNC milling, incremental sheet forming, casting, etc.) were almost impossible due to budget limitations. To retain the original design while minimizing fabrication expenses, we employed panelization with planar panels. This maintained design integrity and notably reduced costs compared to doubly curved production. We utilized the conjugate curve approach to achieve planar panels on this intricate surface. Conjugate Curve Networks approximates non-developable doubly curved surfaces using locally planar curves. These connected curves closely adhere to the surface’s geometry, enabling fabrication of shape-approximating planar panels. We employed planar panels and utilized CNC Laser cutting to trim aluminum sheets. Subsequently, a CNC metal bending machine accurately shaped the panel edges according to the desired form derived from a Grasshopper algorithm. The entire process of cutting and bending for all 200 panels was completed in three days.

Base medial Surface

Conjugated Curve Network

Selectec Conjugated Curves

Planarity Analysis

Planar Quad Panels Columns and Windows Frame OSB Floor Tiles

waffle strips overlap detail

Waffle Structure

Panels connection to waffle

Base Structure

Intersection between panels and waffle

Connection between two panels

Detail Design Every Elemnt of the Structure were devided into smaller parts due to plywood sheet size limits. The parts were connected using overlapping system in which every an array of 6 bolts were used in that area to connect the pieces. For intersection areas were structural elements of different directions of the grid meet eachother, a cross lap joint were used. All these details added to the structure using an algorithm that facilitates the modeling process from speed and accuracy point of view.

Hedracrete Participant CAAI, Tehran, Iran

Jul. 2016 -Mar. 2017 13

Hedracrete Hedracrete is a unique research project aiming to address three important topics in the field of digital design and fabrication. These topics include efficient structural form finding in three dimensions, fabrication of complex spatial systems, and the innovative use of conventional materials. The form of the structure is a funicular polyhedral frame comprised of both compression-only and tension-only members. The structural concept has been designed using 3D graphic statics, which is state-of-the-art geometric structural design method. This method has been recently developed based on a 150-year-old proposition, and Hedracrete is the first built prototype designed using this method.

Form Finding The structure’s funicular polyhedral frame, a blend of compression and tensile elements, stands 3.33 m tall, spanning 5.4 m between three supports. With 45 joints, 54 compression, and 30 tension members, it showcases 3D graphic statics—a cutting-edge design method. Hedracrete, the first prototype using this, serves as a proof of concept, allowing designers to manipulate internal forces.

Force Diagram

Form Diagram

My Role and Impact In this project, I worked with the volumetric team. After achieving static equilibrium, we translated the wire-frame structural concept into a detailed architectural volumetric model. The architectural model is comprised of nodes and members. The depth of the cross section of each member corresponds to the magnitude of its internal force (ranges from 15 to 25 cm) derived from the 3DGS model. The most challenging task in designing the volume of the structure was to derive the geometry of the nodes. Each member of a joint has a unique force magnitude and therefore unique cross sectional depth. To nd an appropriate geometry for the node that can smoothly combine dierent member sizes, specic mathematical denition was developed based on the topology of its convex hull .

VOLUMETRIC DESIGN (a) Locating intersection planes on each bar, regarding the thickness of elements, extracted from force diagram. (b) Intersecting the convex hull faces touching a bar with the plane of each bar. (c) Trimming intersection lines with a circle whose diameter is equal to bar thickness. (d) Drawing Polygon cross sections through intersection between circumscribed circle and main projected and bisector lines. (e) Vertex Connectivity: 1. Each pair of vertices that touches the same internal convex hull face is connected by a straight line (red ones) 2. Each set of three vertices that is located in an interior cell of convex hull must be connected with a triangular polyline (f) Creating the base mesh for applying the smooth algorithm (g) Moving each polygonal section towards the relative bar in order to guarantee the tangent continuity of joints and arms. (h) Moving corner edges of base mesh towards neighboring faces in order to add a fillet=like effect to the final volume and retain polygonal character of cross sections during smoothing algorithm (i) Applying the smooth algorithm.

ri α

k ri

(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

Pi Pi

compression-only and tension-only members

Displacement

Materialozation

Fabrication

Innovating concrete use, we employed glass fiber reinforced concrete (GFRC) for prefabricated components. Perlite, pumice, silica fume, and glass fibers reduced weight, while design consistency was maintained with concrete tensile members

Our primary goal was cost-effective fabrication. Limited by a $8500 budget, we used a 3-axis CNC machine and CNC foam cutter. Employing three-fold symmetry and Styrofoam molds minimized construction time and costs

Tial Al Irfan Competition Competition The Alliance, Tehran, Iran

Jul. 2020

Form Fin

The formtaion of iso-surface based on two net on customized Medial surface and Marching Cube An iso-surface is a three-dimensional analog a surface that represents points of a constant v temperature, velocity, density) within a volume words, it is a level set of a continuous function 3D-space. From a conceptual point of view, the present moment of the past and future, which are eq sustainable development. The lines that represent and the future (red lines) weave together in a dy the Z axis to form the inbetween surface of the sc

Pattern Formation

Pattern Formation on Iso-Surface

The origin of any culture and nation is the key to build the future. The futuristic design of this sculpture also proves the progressive attitude of Omani nation which craves for a bright future. This sculpture captures the patterns common in Omani motifs, as circles and connected strangled lines, to enrich the concept and to honor the national, cultural and historical heritage. The circle signifies the flexibility and tolerance and circulation of energy through the generations. The lines are not cut or interrupted as the national, family and tribal bonds are everlasting. The colors also root in the rich background of Omani art.

Front View

nding Process

twork of lines based e algorithms. g of an isoline. It is value (e.g. pressure, e of space; in other n whose domain is

t time is the binding qually important for t the past (blue lines) ynamic way towards culpture. Step I

Step II

Step III

Step IV

Step V

Step VI

202057 21

202338 202339

Planar Hexagonal Meshing Research Development and Implementation The Alliance, Tehran, Iran

Nov. 2019 23

Planar Hexagonal Meshing This study explores the possibility of tessellating generative medial surfaces with planar hexagonal panels using an agent-based computational approach. To manage the cost of creating doubly curved surfaces, our aim is to panelize them with planar panels, thus supporting cost-effective fabrication. Before this research, we established a computational method to generate the medial surface. The idea for this study originated as we aimed to create a strong algorithm that can generate final planar panels while considering material, fabrication, and construction constraints in the design process.

Desired angles for neighboring triangles for both concave and convex curvature

Coputational process The process begins with the creation of a valence 6 mesh surface. The subsequent steps involve dividing the mesh faces into two sets: a central face and its neighboring triangles. By establishing intersection points through these neighboring triangles, the algorithm forms connections between these points and the corners of the central triangle. This process is then extended to the other mesh faces, resulting in the extraction of planar hexagonal panels from the valence 6 mesh surface.

Convex Planar Hexagonal Meshing

1. Relationship of triangulated mesh and final planar convex hexagonal mesh resulted by Tangent Plane Intersection (TPI) method.

2. Relationship of triangulated mesh and final planar convex hexagonal mesh resulted by Inscribed Triangulation method.

3. Dividing the triangulation mesh into to subcategories by which each half is acts differently regarding the final Planar Convex Hexagonal re-meshing.

Concave Planar Hexagonal Meshing

4. Relationship of triangulated mesh and final planar concave hexagonal mesh resulted by Tangent Plane Intersection (TPI) method.

5. Relationship of triangulated mesh and final planar concave hexagonal mesh resulted by Inscribed Triangulation method.

6. Dividing the triangulation mesh into to subcategories by which each half is acts differently regarding the final Planar Concave Hexagonal re-meshing. 25

Efficient Valence-6 Mesh Surface Generation through Agent-Based Model Forces

Force01 : The forces reshape triangular mesh agents, positioning vertices on the iso-surface with reference to two curve sets. Additionally, each agent maintains uniform spacing with its neighboring agents.

Force02 : Forces that modifies agents of the triangulated mesh in a way that best fits the conditions explained in the previous page. 26

Hexagonal Planar Panels Across Varied Surface Curvatures

Positive Curvature

Negative Curvature

These images demonstrate the algorithm’s robustness across different surface curvatures. It excels in generating planar hexagonal panels for concave and convex surfaces, as well as those with mixed curvature, where challenges arise during shifts between positive and negative curvature.

Combination of Negative & Positive Curvature

Employing this methodology offers a compelling avenue for rationalizing architectural forms, leading to substantial reductions in fabrication costs while preserving the foundational design integrity with minimal alteration. 27

StressNav Precision Computational Designer Taubman College, Michigan, USA 28

Mar. 2023

Hedracrete This project introduces an inventive approach to robot path generation for rod bending, achieved through the implementation of a computational agent-based design method. The initial phase involves the strategic placement of rods using computational form-finding techniques, meticulously aligned with fabrication constraints. Anchoring the process is an analyzed shell structure, where stress levels are visually represented through vertex colors. Agents’ behavior is intricately molded by diverse parameters, including inter-agent distance, field of view angle, and stress sensitivity. These elements converge to create

a dynamic and adaptable system, driving distinct outcomes. The project’s workflow commences by establishing a well-defined mesh surface, onto which stress data is meticulously mapped. Crucially, this innovative approach is meticulously programmed in Python within the Grasshopper3D environment. This programming prowess enables the orchestration of particles that gracefully traverse the mesh surface, homing in on vertices with elevated stress levels. As a result, the project marries computational sophistication with agent-based design, reshaping the landscape of robot-assisted rod bending techniques.

Rule 01 - Viewing Angle: Vital in our agent-based model, determining how far agents see. Wider view means agents check more spots, leading to curvier paths towards stress areas. By considering the bending machine limits, we maintained angles under 60 degrees, ensuring trajectories remain close to straight lines.

Rule 02 - circle-packing: The next important rule is called circle-packing. This means that as agents move around, they need to stay a certain distance away from their closest neighbor. If they get too close, they are pushed apart. This helps make sure there is enough space between the rods, so they can fit nicely together when we put them in place. Rule 03 - Stress sensitivity: The next important rule is called circle-packing. This means that as agents move around, they need to stay a certain distance away from their closest neighbor.

The initial diagram presents a synclastic mesh illustrating stress distribution, where higher stress is depicted by brighter colors. Subsequent Diagrams showcase agents’ paths, maintaining uniform parameters—agent count, stress sensitivity—while differing in field of view angles: 60 and 120 degrees respectively.

In these examples, all parameters remain consistent except for the stress distribution on the given mesh surface, and the impact of the stress pattern on the agents’ path can be observed.

Intersections between agents’ paths are inevit subsequent algorithm was developed after rod introduces kinks to polylines, effectively preve

table but unsuitable for rod assembly. To address this issue, a d path generation. This algorithm identifies intersections and enting rod collisions.

Robotic rod bending setup at Taubman college fablab

Medial Space Workshop tutor Arj Innovation School, Tehran, Iran

Jul. 2019 35

Design & Rationalization Process There are two main procedures for• drawing the minimal surfaces, the subdivision modeling and the formula. In the first process, we do have some limits in the production and controlling the complex forms, and in the second process, we .are not able to control the form The third process is the idea of Medial• Surface, which was published by Daniel Parker. According to the research done by him, the medial surface is another way of generalizing from 2 to 3D, which is arguably more natural. Primarily, we had an (N)Dimensional space partitioned according to the proximity of (N-2)D objects, and the boundaries were (N-1)D objects. So taking N=3, we have a division of 3D space by surfaces according to proximity .to lines On the other hand, the medial surface• could be considered as the locus of some points of the space in a way that the subtraction of their distance from two curves is similar. Choosing this method carries some positive points, such as the ability to control the complex 3d surfaces by the use of 3d curves, which are more control.lable The Medial Space workshop gave us• the opportunity to find out the potentials .of the method mentioned above

Design & Rationalization Process The outcomes of the workshop can be• :divided into four main groups The first group: checking the use of• transformations in order to produce the primary curves. The participants were able to find some unpredictable and unique curves by surveying the effects of transformation such as mirror and copy and the process of their mixture. The outcome of this group was the algorithm of a two-dimensional matrix from .transformation curves

The second group: the participants based their activities on the base of the surfaces and, with studying the typology of their forms and drawing their forming groups, tried to redraw or reread the curves. The produced forms of this group contain both the minimal surface gene and the newly .added layers

Base Line Set

Copy X Copy Y

The third group: the attendees tried to produce Porous and complex surfaces with the use of the growth of the continuous and woven curves. The movement of the curves in the process of growth in the random directions gives the forms the .possibility to be much more unpredictable

Copy X

Copy Y

Copy Z

Copy X Copy Z

Copy Y Xopy Z

Copy X Copy Y Copy Z

The distinctive feature of the fourth group, in contrast to the others, was the emphasis on studying simpler curves and exerting greater influence on the curve-producing parameters, including length, degree, and scale. Members of this group were able to observe the .effects on the curves by manipulating these parameters

Autodesk Forma Participant Denver, Colorado, USA

Oct. 2025

Received the Inaugural Autodesk ACADIA BIPOC Student Scholarship for Acadia 2023. Participated in a workshop on Autodesk Forma, the advanced AEC design platform, during the Acadia 2023 conference. Forma streamlines early design with layout tools and blocking studies, allowing users to explore multiple scenarios and predict outcomes. Explored site analyses like daylight potential, microclimate, noise, energy, sun hours, and wind during the workshop. Integrated Autodesk Forma for detailed insights into early-stage proposals, enhancing planning for economic buildability, livability, and compliance across low-rise, mid-rise, and high-rise buildings.

High-rise Mid-rise

Low-rise

Sun hours 42

Microclimate

Wind 43

PSCo. Pavilion Computational Designer, Toolpath Designer The Alliance, Tehran, Iran May. 2018 44

PSCO Design & Rationalization Process In the design process, the project consists of three phases: Designing the base geometry based on the mathematical and geometrical rules of medial surfaces. The form is created by controlling the shape and relationship of two sets of curve networks in the third dimension, known as the Skeleton Curve Network. This basic form must be feasible within physical conditions and reach the area of the selected robots, ensuring no limitations during the assembly phase regarding robot access.

In the second phase, a series of geometrical optimizations were held to transform the base surface into a surface with soap film characteristics. The mathematical algorithms applied to the surface at this stage are crucial as they serve as input for the rationalization phase (phase 3) and can impact the penalization characteristics. In the final phase, a network of planar quad cells was extracted from the conjugated curve network of the optimized surface.

Base Minimal Surface

Form Adjustment based on the reach of the robots

Conjugated Curve Network

Base Minimal Surface

6.4 mm

0.0 mm

Planarity Analyse

Detail Design & Digital Fabrication Process For converting the 2D panel system extracted from the design and rationalization process into a physical system, one must consider the physical world rules, conditions, and limitations of the fabrication machines. The most suitable machine for milling the panels of the project was a 5-axis milling machine, as all the edges exhibit conic properties based on the location of the panel in the form and the angles of its edges with neighboring panels. However, a limitation in this project was finding a way to fabricate each panel with a 3-axis milling machine. Thus, a system consisting of 3 sets and 14 parts was designed. The first set comprised the front and back faces of each panel, extracted by offsetting the base panels system to both sides in 3D space. The second set included the edge parts of each panel, and the third set consisted of spacer elements that serve both as the spacers between the front and back faces and in controlling the angles between edge elements and these two faces. After defining the parts, a system of dovetail detailing was used to connect and locate each part of the 3-dimensional panels with respect to the neighboring elements that intersect with them. With this system, one can fabricate a precise 3-dimensional panel that retains all the geometrical properties of the virtually designed one.

Front Face

Spacers

Panel Edges

Back Face

Robotic Assembly To facilitate the robotic assembly of the final piece, a set of physical and electromechanical tools was added to the system. Initially, there must be a base structure capable of precisely locating the robots in physical space, aligning with the distance and orientation properties of the virtual space. This structure also serves as the foundational support for the robotic system, capable of bearing the reaction forces of the robots in their bases. Another tool added to the system was a vacuum gripper for each robot. The vacuum grippers are designed to handle the heaviest pieces of the structure. The one selected for the project has a holding force of 900N, enabling it to pick and hold an object weighing up to 50kg. In addition to the vacuum grippers, a set of electrical parts was added to the robot controller for setting I/O commands and controlling the gripper from the computer. Also, a picking table was placed in front of each robot. These tables feature picking guides, allowing for the calibration of each panel based on the orientation defined in the robotic simulation. Assembly Scenario During the assembly process, a set of tasks was defined to facilitate robot-human collaboration. Robots were responsible for picking and positioning tasks, while humans were responsible for placing panels on tables and securing each panel in the 3-dimensional world after being located by the robots.

TNSB Pavilion Tehran National Sculpture Biennial

Professional Tehran.fabtory & The Alliance Tehran, Iran

Sep. 2020

TNSB Pavilion This project was initiated in response to an invitation to participate in the Tehran National Sculpture Biennial. It entails the design of a vertical pavilion constructed from timber, with the primary goal of reducing the structure’s weight. Recognizing reciprocal framing as the most effective method, we aimed to simulate optimal structural behavior

The initial design of the surface provides users with the opportunity to engage in the space shaped by the structure.

Applying the agent-based model results in obtaining a valence six mesh, considered the primary prerequisite for generating an integrated reciprocal frame network.

The dual mesh is generated from the intersection of 3D Voronoi cells around the agents with the double-curved surface.

The dual network of the dual mesh results in a valence six mesh

A C# component has been scripted for two primary reasons. Firstly, the script is designed to rotate each edge of a triangular valence six mesh to achieve the optimal reciprocal frame network while considering structural behavior.

Secondly, the script minimizes the division between beams to streamline the robotic milling process

Plastic Architecture Researcher Dart Lab, Michigan, USA 56

Nov. 2022

Plastic Architecture This project develops computational design and robotic 3d printing technologies for an integrated building envelope system that combines the many functions of the conventional floor-wall-roof systems. Instead of assembling the many layers of cladding and plastic sheets to create weather resistance, vapor, and moisture barriers, the cladding and barriers are printed from plastic in one process. The focus of this research is to develop design solutions to integrate voids that would allow harboring translucent insulation materials like silica gel and phase change materials (PCM) for energy storage and to develop fabrication methods for successful 3D printing of the resulting form in full scale. In the prototype presented here, two topological regions are created. One connects an inner void with the outside and inside of the façade through apertures, and the other connects the inner void of the outer layer and inner layer.

Diagram of the robotic Pellet extrusion system with a continuous feeding system The automated pellet feeding system transfers pellets from a 30L hopper (a) via a pipe (b) to a smaller hopper (c). The end effector consists of a servo-driven extrusion screw and three zone heated barrel (d) and nozzle (e). The heated bed (h) is constructed of aluminum slats attached to a thick aluminum plate needed to ease the dismounting of the 3d printed part after 3d printing (g).

My Role and Impact I was the computational designer for this project. Initially, I designed the overall envelope with a focus on practical integration: Sun-shading, Visual connection, acoustics, structure, insulation, and ventilation. Subsequently, I developed a specialized contouring algorithm that aligned with the constraints of our thermoplastic extrusion setup. To enhance envelope rigidity without traditional infill, I integrated a diffusion algorithm. In the next phase, I intricately planned printing paths. This involved strategic lead-in/out maneuvers, an innovative raft design to bolster adhesion while printing, and optimal TCP orientations— all achieved through Grasshopper3D. The project showcases cutting-edge design and computational prowess.

On the left, the design lacks a diffusion pattern, causing shaking during printing due to thin 6mm filament and no infill. On the right, the same form is seen with the diffusion pattern applied. This configuration brings print layers into contact every few centimeters, resulting in a significant enhancement of print rigidity and quality.

The outer surface is corrugated through a “reaction diffusion” algorithm, producing rib-like stiffeners which enhance the structural stability of the outer surface. Novel toolpath methods were developed to enable fabrication of this complex topology. Future work in this area will investigate the addition of translucent insulation materials like silica gel, as well as phase change materials (PCM) for energy storage. These materials can be placed within the envelope according to solar gain in interconnected passages which allow for efficient thermal transfer.

Dimensions of each panel: 2270 X1170 X200 Material: thermoplastic PETG Volume of material for one panel: 41.3 liters of polymer Weight of one panel: 44.5 kilograms Printing time of each panel: 44 hours Number of mesh faces in the low-res panel: 70,000 Number of mesh faces in the high-res panel: 840,000 Toolpath Length in low resolution panel: 10,323 meters Toolpath Length in high resolution panel: 10,333 meters Show manipulation of mesh based on the generated recursive diffusion pattern. A more detailed diffusion pattern would require higher mesh resolution (up) in comparison to the less branched and detailed pattern (down).

Generative Mix Researcher, Robotic 3D Printing Specialist Dart Lab, Michigan, USA Nov. 2022 62

Generative Mix This project is an exploration of Robotic 3d printing of carbon fiber reinforced plastic (CFRP) facade and mullions. Where we were trying to produce a mullion facade system by robotically 3d printing both the mulion ‘s structure and the glazing. The computational design process begans by integration of 3d topology optimazation for the structure and a 2d topology optimization for the glazing.

Printing the transparent section of the structure, intended for use as glazing. To achieve a transparent effect, clear PETG is utilized for printing this component

Shifting from glazing to printing the main structure, the surface was strengthened by introducing stress lines made of carbon fiber.

Printing the topologically optimized structure out of carbon fiber. As the transparent surface and the main structure were printed continuously, there was no need for any post-processing to glue or attach them together 65

Aligning the lead-in and lead-out moments for better surface quality.

Implementing a sorting algorithm to identify the closest island to the printed contour, aiming to reduce printing time.

A non-planar printing test, allowing for printing sharp overhang angles without the need for supports

With precise control over printing parameters like cooling, robot speed, and extrusion rate, achieving sharp overhang angles in printing becomes possible

Shell Wall Researcher, Robotic 3d Concrete Printing Specialist DART Lab, Michigan, USA Feb. 2023 68

ShellWall Shell Wall demonstrator is the first lightweight, structurally DART’s innovative 3D printing method allows for wastereinforced freeform concrete wall ever 3D printed. This free concrete construction and efficient use of material innovative wall system features a geometry optimized to by placing it precisely where it’s needed for structural support its load case, with material distributed in a hierpurposes. DART’s 3D printing method also facilitates the archical grid of curved ribs ranging in diameter from 65 practical implementation of 3D concrete printing by using to 150 millimeters. The non-load-bearing areas between commonly available concrete rather than relying on highly these ribs are just 6.5 to 8 centimeters deep, enabling the specialized mixes. Shell Wall demonstrator uses a sigsandwiching of insulation between two concrete shells nificantly smaller amount of concrete and rebar than the that are only 2.5 millimeters thick. The fields of concrete much larger quantities that would typically be required for between the ribs are domed to increase stability and mini- a wall of the same dimensions. Additionally, DART develmize material usage. Shell Wall weighs only 160 kilograms oped a lightweight and affordable 3D concrete printing - a 72% reduction in weight compared to a conventional, system for Shell Wall to increase accessibility. solid concrete wall of equivalent size.

D A

My Role and Impact I headed the first robotic 3D concrete printing at DART Lab. I designed a setup with a UR 10e robot (A), progressive cavity pump (B), Beckhoff PLC (C), and 1k concrete 3D printing nozzle (D). By merging the PLC and PC pump, I achieved precise control, allowing adaptable non-planar printing for different layer heights. I also created two algorithms for intricate contours and optimal plane definition. This project showcases my role in advancing robotic concrete printing at its core.

The curved reinforced pipes posed a challenge for integrating rebars after printing the entire wall. To overcome this, we opted to divide the rebars into three sections, allowing for separate insertion and casting.

Branch Wall Researcher, Robotic 3d Concrete Printing Specialist DART Lab, Michigan, USA Jun. 2023

BranchWall Innovating 3D Concrete Printing (3DCP), this project unlocks efficiency by strategically placing material where needed, minimizing waste. Unlike prevalent practices, it integrates topology optimization (TO) for material reduction and intricate geometric features. Overcoming challenges, it introduces Geometrically Informed Non-Planar toolpath and Variable Material Deposition, producing ultra-lightweight topology-optimized building elements. With advanced toolpath strategies, a load-bearing Branch Wall, 68% more material-efficient than traditional methods, showcases the success of a robotic non-planar 3DCP process in fabricating structurally optimized, complex forms.

Topology Optimization:

The left picture displays the load’s position and bounding box. In the middle are rough mesh images from optimization. The right image reveals the optimized design resulting from the load and support conditions.

Remeshing: The topology

optimization process’s output is improved by considering rebar and insulation integration, structural performance, and aesthetic considerations.

Toolpath Design: To gen-

erate the non-planar toolpath, the form is initially broken down into simpler sections. Subsequently, the non-planar toolpath is generated by integrating the heat method.

Sequential casting : Considering the complexity of the wall, we divided the form into two parts to simplify the integration of rebar and insulation during the casting process. Subsequently, the second part of the form was 3D printed. Similar to the first part, rebars and insulation were integrated, followed by the casting process.